Direct injection contact apparatus for severe services

FIELD OF THE INVENTION

A contact apparatus for heat and mass transfer operations that require extended service life considerations and/or frequent cleaning to maintain operability.

BACKGROUND OF THE INVENTION

Various devices exist to facilitate simultaneous heat and mass transfer operations between two or more fluids, the most common application being the heating of clean water using dry steam while providing for quiet operation. Most of these devices are unsuitable for applications in the chemical and refining industries, which often involve viscous liquids, high solids loadings, erosive materials, or wet/dirty vapor streams.

In such “severe applications,” clogging of tight internal passages often is quick and complete. Failure of internal components related to impingement damage or erosion is not uncommon. In “severe applications,” downtime for maintenance is not normally available without great cost due to lost production potential and the inherent safety/environmental risks associated with startups or shutdowns. A need exists for a direct injection contacting apparatus of durable construction that will function reliably in severe applications and will continuously operate over an extended lifetime with minimal maintenance.

SUMMARY OF THE INVENTION

An apparatus for directly contacting a first fluid with a second fluid, said apparatus comprising; a sealed chamber assembly comprising a chamber wall defining a chamber bore having a chamber bore diameter and a chamber longitudinal axis, said chamber wall comprising an injection port, said injection port being in fluid communication with said second fluid; a combining tube comprising a combining tube wall defining a combining tube bore having a combining tube bore diameter that is less than said chamber bore diameter and having a combining tube longitudinal axis which is substantially the same as said chamber longitudinal axis, said combining tube bore comprising an upstream port and a downstream port in fluid communication with said first fluid, said chamber wall and said combining tube wall defining an annular space therebetween; said combining tube wall comprising an upstream set of perforations adjacent to said upstream port, a downstream set of perforations adjacent to said downstream port, and an unperforated section between said upstream set of perforations and said downstream set of perforations, said unperforated section being adjacent to said injection port; said injection port being adapted to prevent said second fluid from directly impinging said combining tube wall; said sealed chamber assembly and said perforations being adapted to produce a turbulent flow of said first fluid and said second fluid within said combining tube bore upon injection of said second fluid through said injection port, said turbulent flow being consistent with non-fouling operation of said apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exploded side view of the components of an embodiment of the present invention.

FIG. 2 illustrates a side elevational view showing a longitudinal cross section of an embodiment of the present invention taken along section line <b>2</b> in FIG. <b>3</b>.

FIG. 3 illustrates a end elevational view taken along section line <b>3</b> shown in FIG. <b>2</b>.

FIGS. 4, <b>5</b> and <b>6</b> illustrate axial cross sections of the combining tube <b>108</b> taken along the section lines shown in FIG. <b>2</b>.

FIG. 7 illustrates a side elevational view showing the relationship between the stinger discharge end <b>108</b><i>b </i>and the outlet end closure flange <b>302</b>.

DETAILED DESCRIPTION

The present application provides a direct injection contact apparatus <b>10</b> that avoids or reduces the shortcomings noted above. In a preferred embodiment, the contact apparatus <b>10</b> of the present invention comprises a three part slip fit sealed chamber assembly providing for the direct contact between a first fluid <b>120</b> and a second fluid <b>220</b> (FIG. <b>2</b>). The first fluid <b>120</b> flows longitudinally through a conduit within the chamber assembly wherein said first fluid <b>120</b> is contacted by said second fluid <b>220</b> through the perforations <b>108</b><i>a </i>(FIG. 1) along the conduit wall. The perforations <b>108</b><i>a </i>are distributed along the conduit wall in a manner to reduce fouling and to facilitate a concurrent turbulent flow. The contact apparatus <b>10</b> will be described in more detail with reference to the embodiment illustrated in the drawings. The drawings are illustrative only, and are not to be construed as limiting the invention, which is defined in the claims.

Referring to FIG. 1, contact apparatus <b>10</b> is comprised of stinger assembly <b>100</b>, chamber assembly <b>200</b>, outlet assembly <b>300</b>, two chamber gaskets <b>500</b>, closure bolts <b>400</b>, and an equal number of closure nuts <b>402</b>. Stinger assembly <b>100</b> forms a liquid conduit extending from the point of entry <b>102</b> of first fluid <b>120</b>, through chamber assembly <b>200</b>, and into outlet assembly <b>300</b>. In a preferred embodiment, stinger assembly <b>100</b> is comprised of first inlet connection <b>102</b>, inlet transition <b>104</b>, combining tube <b>108</b>, and stinger end closure flange <b>106</b>.

Fluid preferably enters stinger assembly <b>100</b> through first inlet connection <b>102</b>. First inlet connection <b>102</b> is a standard piping connection chosen to facilitate installation of the assembled contact apparatus <b>10</b> into the process piping arrangement. In a preferred embodiment, a first inlet stub end <b>102</b><i>a</i>, first inlet lap joint flange <b>102</b><i>b</i>, and first inlet flange retainers <b>102</b><i>c </i>comprise first inlet connection <b>102</b> as shown in FIG. <b>1</b> and FIG. <b>2</b>. In the illustrated embodiment, first inlet flange retainers <b>106</b><i>c </i>are small weld beads on the outer surface of stub end <b>102</b><i>a </i>which restrict lateral movement of first inlet lap joint flange <b>102</b><i>b </i>along stinger assembly <b>100</b>. A rotationally oriented connection such as a raised face weld neck flange or another non-rotationally oriented connection such as a sanitary fitting may be used for first inlet connection <b>102</b> in other embodiments of the invention. Non-rotationally oriented connections, such as the lap joint-stub end combination of the illustrated preferred embodiment reduce fabrication, assembly, installation, and maintenance manhour requirements.

In a preferred embodiment, inlet transition <b>104</b> is a tubular component of circular cross section connected at one end to first inlet connection <b>102</b> at first inlet stub end <b>102</b><i>a</i>, and at an opposed end to combining tube <b>108</b> in such a way as to maintain a common longitudinal axis X—X for all components of stinger assembly <b>100</b>. The internal diameter of inlet transition <b>104</b> is nominally the same as that of first inlet connection <b>102</b> at the point of connection <b>103</b><i>a </i>to said first inlet connection <b>102</b>, gradually transitioning to the same nominal internal diameter <b>103</b><i>b </i>as combining tube <b>108</b> at the point of connection to said combining tube <b>108</b>. One skilled in the art may readily recognize that inlet transition <b>104</b> may be unnecessary in other embodiments of the present invention.

In a preferred embodiment, combining tube <b>108</b> is a tubular component of circular cross section fabricated from seamless pipe having a wall thickness corresponding to schedule 80 or one weight class higher than that used for the first fluid <b>120</b> process inlet piping, whichever is greater. The heavy construction of combining tube <b>108</b> contributes to enhanced life and reduced noise transmission. The nominal diameter <b>107</b> of the pipe used to fabricate combining tube <b>108</b> in a preferred embodiment is chosen to maintain a liquid flow velocity based on inlet conditions to combining tube <b>108</b> of from about 1.2 m/sec to about 3.6 m/sec. This velocity range minimizes solids deposition and erosion damage in combining tube <b>108</b>.

Combining tube <b>108</b> extends from its junction with inlet transition <b>104</b> through stinger end closure flange <b>106</b>, which is designed to mate with either first chamber closure flange <b>202</b> or second chamber closure flange <b>204</b> at stinger end closure flange sealing face <b>106</b><i>a</i>. Upon mating at either first chamber closure flange <b>202</b> or second chamber closure flange <b>204</b>, combining tube <b>108</b> is positioned within mating hole <b>308</b> of outlet assembly <b>300</b> comprising a running fit between stinger discharge end <b>108</b><i>b </i>and mating hole <b>308</b>. In a preferred embodiment stinger end closure flange <b>106</b> consists of a raised face blind flange which has been axially bored to accommodate passage of combining tube <b>108</b> in a manner such that stinger end closure flange sealing face <b>106</b><i>a </i>faces away from first inlet connection <b>102</b> and is perpendicular in all respects to the longitudinal axis X—X for all other components of stinger section <b>100</b>. Stinger end closure flange <b>106</b> is attached to combining tube <b>108</b> by a complete fusion weld with full joint penetration in a manner such that a common longitudinal axis X—X is maintained between stinger end closure flange <b>106</b> and combining tube <b>108</b>. In a preferred embodiment, lateral placement of stinger end closure flange <b>106</b> is at a point 25 to 30 mm downstream of the weld between combining tube <b>108</b> and inlet transition <b>104</b> in order to minimize overlap of the heat affected zones resulting from the two welding procedures.

Stinger discharge end <b>108</b><i>b </i>is machined to slip through a mating hole <b>308</b> in outlet end closure flange <b>302</b> comprising a loose running fit along common longitudinal axis X—X. The slip fit clearance <b>504</b> relieves mechanical stresses induced by temperature differentials-between fluid streams. The slip fit clearance <b>504</b> also allows for absorption of a substantial amount of the shock force generated by rapid vapor bubble collapse by the combining tube <b>108</b> with very limited sound transmission.

As shown in FIG. <b>2</b> and FIG. 7, the machined area of combining tube <b>108</b> comprising stinger discharge end <b>108</b><i>b </i>preferably begins at the plane defined by the sealing face <b>302</b><i>a </i>(FIG. 1) of outlet end closure flange <b>302</b> and continues to tip bevel <b>108</b><i>c</i>. In a preferred embodiment, said machined area protrudes 5 mm to 10 mm beyond the downstream end <b>308</b><i>b </i>(FIG. 1) of mating hole <b>308</b>. The protrusion of tip bevel <b>108</b><i>c</i>, beyond <b>308</b><i>b</i>, results in easier unit disassembly when handling fouling liquids such as latex.

In a preferred embodiment illustrated by FIG. 7, tip bevel <b>108</b><i>c </i>begins at a point 5 mm to 10 mm from the downstream end of combining tube <b>108</b>, proceeding inward to constitute a bevel at an angle of about 10° to about 30° relative to the longitudinal axis X—X of stinger section <b>100</b>. Bore bevel <b>308</b><i>a </i>(FIG. <b>1</b> and FIG. 7) on the upstream side of outlet end closure flange <b>302</b> begins preferably 5 mm to 10 mm inside mating hole <b>308</b> proceeding upstream to outlet end closure flange sealing face <b>302</b><i>a </i>at an angle of about 30° to about 45° to longitudinal axis X—X of mating hole <b>308</b>. The use of tip bevel <b>108</b><i>c </i>and bore bevel <b>308</b><i>a </i>simplifies assembly of contact apparatus <b>10</b> by guiding stinger section <b>100</b> and outlet section <b>300</b> into proper alignment along a common longitudinal axis. In a preferred embodiment, slip fit clearance <b>504</b> comprises a running fit with a diameter differential between stinger discharge end <b>108</b><i>b </i>and mating hole <b>308</b> of 0.05 mm to 0.1 mm clearance.

As shown in FIG. <b>1</b> and FIG. 2, the sections <b>110</b>, <b>112</b> of combining tube <b>108</b> exposed to annular space <b>502</b> (FIG. 2) contain a number of combining tube perforations <b>108</b><i>a </i>which form passages for second fluid <b>220</b> to flow from annular space <b>502</b> into combining tube <b>108</b>, where it mixes intimately with first fluid <b>120</b>. Perforations <b>108</b><i>a </i>are grouped into upstream section <b>110</b> and downstream section <b>112</b>, which are separated by unperforated section <b>114</b>.

Referring to FIG. 3, unperforated section <b>114</b> promotes establishment of a rotational flow path for second fluid <b>120</b> as it enters annular space <b>502</b>, minimizing erosive damage to combining tube <b>108</b> and resulting in substantially even pressure distribution preferably along the full length of combining tube <b>108</b>, without obstructing the direct flow path of second fluid <b>120</b>. Unperforated section <b>114</b> is positioned along combining tube <b>108</b> such that it is centered between plane A—A defined by stinger end closure flange sealing face <b>106</b><i>a </i>and plane A-B defined by outlet end closure flange sealing face <b>302</b><i>a </i>in the assembled contacting apparatus <b>10</b>. Unperforated section <b>114</b> extends upstream and downstream from this central point beyond the lateral extents of injection port <b>206</b><i>ca </i>in the assembled contacting apparatus <b>10</b> preferably a distance of 1 cm to 2 cm to promote establishment of the rotational path around the annular space <b>502</b>.

Combining tube perforations <b>108</b><i>a </i>preferably are divided essentially equally between upstream section <b>110</b> and downstream section <b>112</b>. Pattern layout, size, and number of said perforations <b>108</b><i>a </i>within upstream section <b>110</b> and downstream section <b>112</b> may be determined by one skilled in the art using well established engineering principles applied to the process data at hand to produce a desired process result. In a preferred embodiment, perforations <b>108</b><i>a </i>comprise bores having a longitudinal axis and an internal diameter from about 5 mm to about 10 mm, said diameter producing optimal interfacial areas between first fluid <b>120</b> and second fluid <b>220</b> inside combining tube <b>108</b> consistent with non-fouling operation of stinger assembly <b>100</b>. The number of perforations <b>108</b><i>a </i>will vary to accommodate the required flow of second fluid <b>120</b> while minimizing direct contact between the first fluid <b>120</b> and the second fluid <b>220</b>. The length <b>100</b> of combining tube <b>108</b> and correspondingly, the length <b>200</b> of chamber body <b>208</b> will vary to accommodate the number of combining tube perforations <b>108</b><i>a. </i>

Combining tube perforations <b>108</b><i>a </i>are arranged within upstream section <b>110</b> and downstream section <b>112</b> in configurations which yield desired process results. In a preferred embodiment illustrated in FIGS. 1 through 7, perforations <b>108</b><i>a </i>are arranged in circumferential rows having a symmetrical radial pattern of perforations <b>108</b><i>a</i>. The most upstream row <b>108</b><i>d </i>(FIG. 1) of perforations <b>108</b><i>a </i>in said upstream section <b>110</b> is positioned such that the most upstream edge <b>108</b><i>aa </i>(FIG. 2) of perforations <b>108</b><i>a </i>in this row physically contact the plane A—A defined by stinger end closure flange sealing face <b>106</b><i>a</i>. The most downstream row <b>108</b><i>e </i>(FIG. 1) of perforations <b>108</b><i>a </i>in downstream section <b>112</b> is positioned such that a portion, preferably about half of the inner diameter <b>108</b><i>ab </i>(FIG. 2) of perforations <b>108</b><i>a </i>in row <b>108</b><i>e </i>lies downstream of plane A-B defined by outlet end closure flange sealing face <b>302</b><i>a </i>when contact apparatus <b>10</b> is properly assembled. The remaining rows of combining tube perforations <b>108</b><i>a </i>are preferably distributed equally between upstream section <b>110</b> and downstream section <b>112</b>, spaced substantially evenly along the lengths of said two sections. In a preferred embodiment, the minimum distance A-C (FIG. 2) between lines drawn along the longitudinal axis AB of the perforations is at least three times the diameter of the perforations <b>108</b><i>a. </i>

In a preferred embodiment, combining tube perforations <b>108</b><i>a </i>in a given row <b>108</b><i>d</i>, <b>108</b><i>a</i><b>1</b>, <b>108</b><i>a</i><b>2</b>, <b>108</b><i>a</i><b>3</b>, etc., (FIG. 1) are arranged symmetrically around the circumference of the combining tube <b>108</b> with a minimum radial angle RA (FIG. 5) between their longitudinal axes (AJ, AB, FIG. 2) of 45° (FIG. <b>4</b>). Succeeding rows of perforations <b>108</b><i>a </i>are rotationally offset a minimum of about 15° from the previous row, and are arranged to form a repeating pattern of perforations <b>108</b><i>a </i>every three to six rows. In a preferred embodiment, perforations <b>108</b><i>a </i>in a given row are rotationally offset from the previous row by one-third of the radial angle RA. The result is a three row repeating pattern of perforations <b>108</b><i>a</i>. A preferred pattern of rotation for succeeding rows is shown in cross section as follows: <b>102</b><i>e </i>(FIG. <b>4</b>), <b>102</b><i>a</i><b>1</b> (FIG. <b>5</b>), and <b>102</b><i>a</i><b>2</b> (FIG. <b>6</b>). One skilled in the art will recognize that the alignment of combining tube perforations <b>108</b><i>a </i>may vary to produce different process results. The lateral offset may vary from about −15° to about +15° in relation to longitudinal axis X—X. The upstream to downstream angle of said perforations <b>108</b><i>a </i>may vary from about −60° to about +60° in relation to longitudinal axis X—X. In said preferred embodiment, the longitudinal axes (AJ, AB, FIG. 2) of perforations <b>108</b><i>a </i>are substantially in linear alignment with longitudinal axis X—X (i.e. a lateral offset of approximately 0°), and are at an upstream to downstream angle relative to the longitudinal axis X—X of about 45°, resulting in concurrent injection of second fluid <b>220</b> into first fluid <b>120</b>. The foregoing perforation layout results in uniform dispersion of second fluid <b>220</b> into first fluid <b>120</b> with minimal recombination and minimal solid deposition along the internal wall of the combining tube <b>108</b> in fouling applications. One skilled in the art will recognize that other embodiments of the invention may feature combining tube perforations <b>108</b><i>a </i>having other arrangements to produce different process results.

In a preferred embodiment, chamber assembly <b>200</b> comprises first and second chamber closure flanges <b>202</b>, <b>204</b> attached to the ends of chamber body <b>208</b>. Second fluid inlet subassembly <b>206</b> joins chamber body <b>208</b> along its periphery at the midpoint between said first and second chamber closure flanges <b>202</b>, <b>204</b> in such a manner as to induce a tangential flow of second fluid <b>220</b> into the annular space <b>502</b> formed between chamber body <b>208</b> and combining tube <b>108</b> in contact apparatus <b>10</b>.

Referring to FIG. 2, in a preferred embodiment, first and second chamber closure flanges <b>202</b>, <b>204</b> are standard raised face weld neck flanges which bolt to stinger end closure flange <b>106</b> and outlet end closure flange <b>302</b> using closure bolts <b>400</b> and closure nuts <b>402</b>, effectively sealing chamber assembly <b>200</b> around combining tube <b>108</b>. Orientation of chamber assembly <b>200</b> may be altered to produce either clockwise or counterclockwise tangential flow patterns (demonstrated by arrows <b>220</b> in FIG. 3) in annular space <b>502</b> by choosing which chamber closure flange <b>202</b> or <b>204</b> is bolted to stinger assembly <b>100</b> at stinger end closure flange <b>106</b>.

Chamber body <b>208</b> is made of tubular material having a circular cross section, preferably seamless pipe having a nominal size such that the outer surface of combining tube <b>108</b> is not directly impinged by second fluid <b>220</b> as it enters annular space <b>502</b>. In a preferred embodiment (FIGS. <b>1</b> through <b>3</b>), the use of an external configuration for tangential diverter <b>206</b><i>c </i>allows minimal diameter material to be used for chamber body <b>208</b>. In said preferred embodiment, chamber body <b>208</b> is constructed of seamless pipe having an internal diameter such that radial distance AF between the inside wall of chamber body <b>208</b> and the outer wall of combining tube <b>108</b> is from about 40% to about 75% of the inside diameter of second fluid inlet subassembly <b>206</b>. In other embodiments of contact apparatus <b>10</b> which feature different configurations for tangential diverter <b>206</b><i>c </i>or omit tangential diverter <b>206</b><i>c </i>completely, a radial distance AF of up to about 150% of the inside diameter of second fluid inlet subassembly <b>206</b> may be required to prevent direct impingement. The diameter of chamber body <b>208</b> required to prevent direct impingement, as well as the appropriate wall thickness for chamber body <b>208</b> may readily be determined by one skilled in the art using well established engineering principles applied to the process data at hand. Avoiding direct impingement of second fluid <b>220</b> on combining tube allows full rotational flow path development for second fluid <b>220</b> within annular space <b>502</b>, providing even distribution of second fluid <b>220</b> along the full length of combining tube <b>108</b> and minimizing damage to combining tube <b>108</b> by any entrained liquid or solid particles that may be present in second fluid <b>220</b>.

In a preferred embodiment, second fluid inlet subassembly <b>206</b> (FIG. 1) consists of second inlet connection <b>206</b><i>a</i>, second inlet line <b>206</b><i>b</i>, and tangential diverter <b>206</b><i>c</i>. Nominal sizing of all components in second fluid inlet subassembly <b>206</b> may readily be determined by one skilled in the art based on application of established engineering principles to the process operating data at hand.

Second inlet connection <b>206</b><i>a </i>is the conduit by which second fluid <b>220</b> enters contact apparatus <b>10</b> from the process inlet piping. Second inlet connection <b>206</b><i>a </i>is a standard piping connection chosen to facilitate installation of the assembled contact apparatus <b>10</b> into the process piping arrangement. In a preferred embodiment, second inlet stub end <b>206</b><i>aa</i>, second inlet lap joint flange <b>206</b><i>ab</i>, and second inlet flange retainers <b>206</b><i>ac </i>comprise second inlet connection <b>206</b><i>a</i>. In the illustrated embodiment, second inlet flange retainers <b>206</b><i>ac </i>are small weld beads on the outer stub end surface restricting lateral movement of second inlet lap joint flange <b>206</b><i>ab </i>along second fluid inlet subassembly <b>206</b>. A rotationally oriented connection such as a raised face weld neck flange or another non-rotationally oriented connection such as a sanitary fitting may be used for second inlet connection <b>206</b><i>a </i>in other embodiments of the invention. Non-rotationally oriented connections, such as the lap joint-stub end combination of the illustrated preferred embodiment reduce fabrication, assembly, installation, and maintenance manhour requirements.

Second inlet line <b>206</b><i>b </i>connects tangential diverter <b>206</b><i>c </i>to second inlet connection <b>206</b><i>a </i>at second inlet stub end <b>206</b><i>aa</i>. Second inlet line <b>206</b><i>b </i>serves as a spacer to move second inlet connection <b>206</b><i>a </i>away from chamber body <b>208</b> far enough to accommodate insulation of chamber body <b>208</b> while maintaining ease of connection and disconnection of the process piping. In a preferred embodiment shown in FIG. 3, second inlet line <b>206</b><i>b </i>is a straight piece of seamless pipe having a longitudinal axis AG. One skilled in the art will recognize that other embodiments of the invention may utilize fittings such as a concentric pipe reducer in place of straight seamless pipe for inlet subassembly <b>206</b>, or may omit the component entirely.

Tangential diverter <b>206</b><i>c </i>provides a means of establishing a tangential entry for second fluid <b>220</b> into annular space <b>502</b> such that a tangential flow pattern with respect to chamber body <b>208</b> is established for second fluid <b>220</b> within the annular space <b>502</b>. In a preferred embodiment as shown in FIG. 3, tangential diverter <b>206</b><i>c </i>comprises a 90° bend comprising a suitable curvature relative to AG, attached to second inlet line <b>206</b><i>b </i>at the_upstream end and machined to conform to the inside diameter of chamber body <b>208</b> beginning at a tangent point <b>206</b><i>cb </i>on the inside wall of the outer periphery of said <b>900</b> bend at injection port <b>206</b><i>ca</i>. Tangential diverter <b>206</b><i>c </i>is mated to a corresponding opening in chamber body <b>208</b> in a manner such that second fluid inlet subassembly <b>206</b> is perpendicular to the longitudinal axis of chamber body <b>208</b> in the completed chamber assembly <b>200</b>, and tangent point <b>206</b><i>cb </i>is tangent to the inner periphery of chamber body <b>208</b> at the point of attachment to said chamber body <b>208</b>. In the illustrated preferred embodiment, tangential diverter <b>206</b><i>c </i>is attached to chamber body <b>208</b> by complete fusion weld with full penetration, and in a manner which results in no intrusion of second inlet subassembly <b>206</b> past the inner periphery <b>208</b><i>c </i>of chamber body <b>208</b>. Wall thickness of the tangential diverter <b>206</b><i>c </i>is selected so that it is at least as thick as the material used to fabricate chamber body <b>208</b>.

Tangential entries are commonly used in cyclone and centrifugal separator design. Persons of ordinary skill in the art will understand how to fashion a suitable tangential diverter for a given apparatus. See <i>PERRY'S CHEMICAL ENGINEERING HANDBOOK</i>, pp. 14-83-14-84; 17-27-17-39; and 26-31-26-36 (Int'l Version, 7⁷ed. 1997), incorporated herein by reference. One skilled in the art will recognize that tangential diverter <b>206</b><i>c </i>may comprise arrangements other than a machined 90° bend or may be omitted completely in other embodiments of contact apparatus <b>10</b> as long as tangential entry of second fluid <b>220</b> into annular space <b>502</b> is accomplished with no direct impingement on combining tube <b>108</b>.

Referring to FIGS. 1 and 2, outlet assembly <b>300</b> comprises outlet connection <b>306</b>, outlet transition <b>304</b>, and outlet end closure flange <b>302</b>. In a preferred embodiment, outlet end closure flange <b>302</b> is a raised face blind flange designed to mate with either first chamber closure flange <b>202</b> or second chamber closure flange <b>204</b>. Outlet end closure flange <b>302</b> is through bored along longitudinal axis X—X to form mating hole <b>308</b>, which comprises bore bevel <b>308</b><i>a </i>as previously described. In assembled contact apparatus <b>10</b>, stinger discharge end <b>108</b><i>b </i>slides through mating hole <b>308</b>, forming a running slip fit between the two surfaces and effectively sealing chamber assembly <b>200</b> in conjunction with stinger end closure flange <b>106</b>.

Outlet transition <b>304</b> connects outlet end closure flange <b>302</b> and outlet connection <b>306</b> in a manner which maintains longitudinal axis X—X between all components of outlet section <b>300</b>. Outlet transition <b>304</b> forms the transition between the external diameter A-H of the combining tube <b>108</b> and the internal diameter A-I of the outlet connection <b>306</b>. In a preferred embodiment, the internal diameter AJ of outlet transition <b>304</b> at <b>308</b><i>b </i>is 0 mm to 5 mm larger than the external diameter A-H of stinger discharge end <b>108</b><i>b</i>. The internal diameter A-Z at the point of connection <b>306</b><i>d </i>to outlet connection <b>306</b> is nominally the same as that of the process piping to which outlet connection <b>306</b> is to be connected. FIG. <b>1</b> and FIG. 2 illustrate outlet transition <b>304</b> as a standard concentric pipe reducer. One skilled in the art will recognize that in other embodiments of the present invention outlet transition <b>304</b> may comprise other types of configurations such as a straight pipe section, venturi, orifice arrangement, etc., or may be omitted completely based on process application and individual piping arrangements.

Outlet connection <b>306</b> is the point by which mixed fluid <b>320</b>, comprising first fluid <b>120</b> and second fluid <b>220</b>, exits contact apparatus <b>10</b>. Outlet connection <b>306</b> is a standard piping connection chosen to facilitate installation of the present invention into the process piping arrangement. In a preferred embodiment, outlet stub end <b>306</b><i>a</i>, outlet lap joint flange <b>306</b><i>b</i>, and outlet flange retainers <b>306</b><i>c </i>comprise outlet connection <b>306</b>. Outlet flange retainers <b>306</b><i>c </i>are small weld beads on the outer stub end surface to restrict lateral movement of outlet lap joint flange <b>306</b><i>b </i>along outlet assembly <b>300</b>. A rotationally oriented connection such as a raised face weld neck flange or another non-rotationally oriented connection such as a sanitary fitting may be used for outlet connection <b>306</b> in other embodiments of the invention. Non-rotationally oriented connections, such as the lap joint-stub end combination of the illustrated preferred embodiment reduce fabrication, assembly, installation, and maintenance manhour requirements.

The materials and mechanical design specification of closure bolts <b>400</b>, closure nuts <b>402</b>, and chamber gaskets <b>500</b> will vary with each individual application. In a preferred embodiment, an appropriate size and number of lubricant coated bolts, preferably PTFE coated Grade 8 machine bolts and PTFE coated heavy hex nuts are used for closure bolts <b>400</b> and closure nuts <b>402</b> allowing accurate, uniform tightening and ease of assembly and disassembly of these fastener sets. In a preferred embodiment, chamber gasket <b>500</b> is a standard {fraction (1/16)}″ thick ring gasket designed for use with raised face flanges. Filled PTFE-based gasketing materials containing no asbestos such as the various grades of GYLON® gasketing marketed by Garlock Sealing Technologies are generally suitable for chamber gaskets <b>500</b> in most applications due to their chemical resistance and good sealing capability.

Materials of construction and dimensions for all components of contact apparatus <b>10</b> will vary based on the process operating conditions. In all cases where permanent connections are made in the fabrication of any components of the present invention, these connections preferably are made using machining, setup, and welding techniques which result in complete fusion welds with full joint penetration while maintaining component alignment. In a preferred embodiment, all components are subjected to stress relief procedures after welding to eliminate all differential stresses induced during the welding processes and restore original corrosion resistance properties of the materials used to construct said components. Proper procedures for machining, welding, and stress relief can readily be determined by one skilled in the art based on established principles of engineering and materials science.

In practice, the contact apparatus <b>10</b> of the present invention is installed in a vertical orientation, wherein the flow of first fluid <b>120</b> proceeds from top to bottom. Once assembled, the contact apparatus <b>10</b> is installed in a given process by attaching first inlet connection <b>102</b> to the process fluid inlet piping to allow entry of first fluid <b>120</b>. Second inlet connection <b>206</b><i>a </i>is then attached to the process inlet piping to allow entry of second fluid <b>220</b>. Finally, outlet connection <b>306</b> is attached to the process outlet piping to allow egress of mixed fluid <b>320</b> from contact apparatus <b>10</b>.

At commencement of operation, fluid streams are established within the contact apparatus <b>10</b> wherein first fluid <b>120</b> enters contact apparatus <b>10</b> through first inlet connection <b>102</b> flowing through inlet transition <b>104</b> into combining tube <b>108</b>. These components form a fluid conduit within contact apparatus <b>10</b>. Second fluid <b>220</b> enters the contact apparatus <b>10</b> through second fluid inlet subassembly <b>206</b>, flowing tangentially into the annular space <b>502</b> between chamber body <b>208</b> and the outside of combining tube <b>108</b>. Second fluid <b>220</b> flows from annular space <b>502</b> through combining tube perforations <b>108</b><i>a </i>and mixes with first fluid <b>120</b> as it flows through combining tube <b>108</b>. The intimate mixing of first fluid <b>120</b> and second fluid <b>220</b> within combining tube <b>108</b> facilitates heat and mass transfer between the fluids. The mixed fluid <b>320</b> flows from combining tube <b>108</b> at stinger discharge end <b>108</b><i>b</i>, through outlet assembly <b>300</b> and exits contact apparatus <b>10</b> into the process piping via the outlet connection <b>306</b>.

In a preferred embodiment best illustrated in FIG. 2, first fluid <b>120</b> is a liquid and second fluid <b>220</b> is a condensable vapor at saturated conditions and at a higher temperature than first fluid <b>120</b>. In this embodiment, liquid moves as a stream from the liquid inlet process piping through the conduit formed by first inlet stub end <b>102</b><i>a</i>, inlet transition <b>104</b>, combining tube <b>108</b>, outlet transition <b>304</b>, and outlet stub end <b>306</b><i>a</i>. Vapor flows from the vapor inlet process piping through the conduit formed by second inlet stub end <b>206</b><i>aa</i>, second inlet line <b>206</b><i>b</i>, and tangential diverter <b>206</b><i>c </i>into annular space <b>502</b>. The vapor mixes with the liquid stream as the vapor passes through combining tube perforations <b>108</b><i>a </i>into combining tube <b>108</b>, wherein the vapor condenses, giving up its latent heat and part of its sensible heat to the liquid which is warmed in the exchange. The condensed vapor/liquid mixture <b>320</b> flows from combining tube <b>108</b> into outlet transition <b>304</b>, finally exiting contact apparatus <b>10</b> by flowing from outlet stub end <b>306</b><i>a </i>into the liquid outlet process piping.

In said preferred embodiment, as vapor passes through tangential diverter <b>206</b><i>c</i>, a gradual change in flow direction is imposed on the vapor stream. Momentum forces act on the vapor and any solid or liquid material entrained therein, forcing the bulk of the material toward the outer periphery of said diverter <b>206</b><i>c </i>and creating a stratified velocity profile with a region of higher velocity and pressure toward the outer periphery of diverter <b>206</b><i>c </i>and a region of lower velocity and pressure toward the inner periphery of diverter <b>206</b><i>c. </i>

The stratified vapor stream passes through injection port <b>206</b><i>ca </i>into annular space <b>502</b> defined by chamber body <b>208</b> on the outer periphery and combining tube <b>108</b> on the inner periphery, and confined at the ends by stinger closure flange <b>106</b> and outlet closure flange <b>302</b>. The initial high speed tangential flow path of second fluid <b>220</b> at the entry point <b>208</b><i>b </i>induces a bulk rotational motion of the vapor within annular space <b>502</b> around the inner periphery <b>208</b><i>c </i>of chamber body <b>208</b>. Centrifugal forces resulting from the rotational motion act on the vapor causing entrained solids and liquids to separate from the vapor stream and flow along the inside wall <b>208</b><i>a </i>of chamber body <b>208</b> toward outlet closure flange <b>302</b>, where they accumulate. These solids and liquids are eventually swept from annular space <b>502</b> through combining tube perforations <b>108</b><i>a </i>or to a lesser extent through slip fit clearance <b>524</b> into the mixed fluid <b>320</b> by flowing vapor.

The placement of unperforated section <b>114</b> on combining tube <b>108</b> minimizes short-circuiting of vapor flow directly from tangential diverter discharge <b>206</b><i>a </i>through combining tube perforations <b>108</b><i>a</i>, thus helping to establish the longer rotational flow path for vapor within annular space <b>502</b>. As vapor flows around the periphery of annular space <b>502</b>, its velocity is dissipated by frictional forces allowing the vapor to expand evenly along the length of annular space <b>502</b> while maintaining a stratified velocity profile. As illustrated in FIG. 3, the vapor flow spirals inward toward the combining tube <b>108</b> as the velocity continues to dissipate, resulting in a well-distributed pressure profile along the combining tube <b>108</b> at the entrance to combining tube perforations <b>108</b><i>a. </i>

Vapor flows through combining tube perforations <b>108</b><i>a </i>into combining tube <b>108</b> where it mixes with the liquid flowing therein. A shearing action is induced as the high speed vapor jets impinge on the liquid at the exit of combining tube perforations <b>108</b><i>a </i>producing vapor bubbles and inducing vigorous liquid motion as it gives up its kinetic energy to the liquid. The greater the kinetic energy of the vapor stream as it enters the liquid, the smaller the bubble produced and the more aggressive the liquid motion induced. Heat and mass transfer rates are highly dependent upon relative velocities and interfacial areas between the materials involved. Insufficient induction velocity of the vapor into the liquid in combining tube <b>108</b> results in reduced heat and mass transfer rates as well as high vibration and noise levels due to shock waves formed when large vapor bubbles collapse upon condensation.

In the extant embodiment of contact apparatus <b>10</b>, high vapor induction velocities are used to produce very small bubbles and aggressive liquid motion, resulting in extraordinarily high heat and mass transfer rates inside combining tube <b>108</b>. In practice, combining tube perforations <b>108</b><i>a </i>are varied in number and size to produce a perforation exit vapor velocity to bulk liquid velocity ratio preferably over 100:1 and frictional pressure losses resulting from vapor flow through said perforations <b>108</b><i>a </i>greater than 0.3 atm, and preferably greater than 1.0 atm throughout the normal operating range of the contact apparatus <b>10</b> while maintaining bore diameter <b>108</b><i>g </i>of the perforations <b>108</b><i>a </i>preferably between 5 mm and 10 mm. The calculations required to establish the number and size of combining tube perforations <b>108</b><i>a </i>required to achieve this process objective can readily be made by one skilled in the art based on application of well established engineering principles to the process data at hand.

In this preferred embodiment, combining tube perforations <b>108</b><i>a </i>are grouped into upstream section <b>110</b> and downstream section <b>112</b> separated by unperforated section <b>114</b>. Perforations <b>108</b><i>a </i>are drilled at a downstream slant of 30° to 60°, preferably 45° in relation to the longitudinal axis X—X of the combining tube <b>108</b> and are in axial alignment with said longitudinal axis X—X. This results in an unencumbered roughly hyperbolic initial vapor flow path concurrent with the liquid flow. This initial flow path presents minimal opportunity for bubble recombination and the attendant vibration and noise experienced as these congregated bubbles collapse. Combining tube perforations <b>108</b><i>a </i>in this embodiment of the invention are arranged in radial rows having symmetrical radial distribution with a minimum radial angle of 45° between perforations <b>108</b><i>a </i>(FIG. <b>4</b>). Rows of perforations <b>108</b><i>a </i>are arranged in a rotationally offset three row pattern as shown in FIGS. 4, <b>5</b>, and <b>6</b>. This layout pattern and perforation orientation provides a multiplicity of high speed nonintersecting jets of vapor that thoroughly chum the flowing liquid within the combining tube <b>108</b>, inducing highly turbulent eddy flow patterns within the liquid phase. This aggressive fluid motion results in even distribution and rapid condensation of the vapor and promotes maximum turbulence and mixing of the fluids within combining tube <b>108</b>. The overall result is quiet operation and extraordinarily high heat and mass transfer rates over the operating design range for the contacting apparatus <b>10</b>. In condensing, the vapor bubbles give up their latent heat and a portion of their specific heat to the liquid. The warmed liquid flows out of the combining tube <b>108</b> into the outlet transition <b>304</b> as it passes from the chamber assembly <b>200</b>.

A small quantity of vapor also flows through the slip fit clearance <b>504</b> between the stinger discharge end <b>108</b><i>b </i>and the outlet end closure flange <b>302</b>, joining the main liquid flow as it exits contact apparatus <b>10</b> by flowing from the outlet transition <b>304</b> through the outlet stub end <b>306</b><i>a </i>and into the liquid outlet process piping. This small flow helps minimize solids accumulation in the slip fit clearance <b>504</b>, thereby promoting easy disassembly of the unit for maintenance at the proper time.

In operation, shock waves result from the collapse of vapor bubbles as they condense within the combining tube <b>108</b>. The slip fit clearance <b>504</b> at the outlet end closure flange <b>302</b> allows a slight amount of lateral motion of the combining tube <b>108</b>, thus allowing the absorption and dissipation of energy contained in the shock waves in the form of very restricted motion of the combining tube <b>108</b> itself. The absorption and dissipation of this energy through induced motion of the combining tube <b>108</b> promotes quiet operation of the unit throughout its designed operational range. Absorbed energy and stresses from the induced vibration of combining tube <b>108</b> are either dissipated as heat or transferred to the stinger end closure flange <b>106</b> at the base joint with the combining tube <b>108</b>. The heavy duty construction techniques and stress relief used in the fabrication of this joint in the preferred embodiment allow vibrational stresses to be absorbed with no deterioration in the quality of the joint over extended and severe service conditions.

Persons of ordinary skill in the art will recognize that many modifications may be made to the present invention without departing from the spirit and scope of the present invention. The embodiment described herein is meant to be illustrative only and should not be taken as limiting the invention, which is defined in the following claims.